Abrasive article and method of making

ABSTRACT

An abrasive sheet material comprising a first sheet having a first major suface and a second major surface and second sheets having first major surfaces and second major surfaces wherein the second major surfaces of the second sheets are affixed to the first major surface of the first sheet and spaces exist between the second sheets wherein said spaces form pathways that interweave between the second sheets wherein the pathways communicate with each other and form a network of pathways. At least one aperture extends from at least the first major surface of the first sheet to the second major surface of the first sheet and communicates with at least one of the pathways. Abrasive particles are coated onto at least the first major surface of the second sheets forming an abrasive first major surface. When air moves through the pathways by a vacuum source said pathways channel air across and parallel to the work surface while the air is in contact with the work surface thereby providing a sweeping movement of air across the work surface carrying dust with the air for the purpose of vacuuming dust from the work surface.

This application claim benefit to provisional patent application 60/936,264 filed on Jun. 19, 2007 and also to provisional patent application 61/070,819 filed Mar. 26, 2008 and also to provisional patent application 61/126,254 filed May 2, 2008 all of which are hereby incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to surface finishing tools. Particularly, the present invention relates to abrasive sheet materials. More particularly, the present invention relates to abrasive sheet materials that may be connected to tools that have a dust collection means wherein a vacuum may be directed to the abrasive sheet material for the purpose of collecting dust.

2. Description of the Related Art

Dustless sanding tools and abrasive sheet material adapted to be used with dustless sanding tools are well known and widely used in the industry where sanding operations are common. Some commonly used sanding tools that use abrasive sheet material include orbital sanders, palm sanders, back up pads for power tools having dust collection holes and hand tools configured to be dustless sanders. Dust has long been a problem in sanding operations and the need to devise abrasive tools that address collection of dust while sanding is an ever present need. Sanding tools that currently address the problem of dust do so by means of through holes in the abrasive material, typically an abrasive sheet material wherein the through holes communicate with dust collection apertures in a back up pad of a tool for example an orbital sander has a back up pad that typically has a five hole or an eight hole pattern of dust collection holes in the back up pad. An abrasive sheet typically a circular abrasive sheet has matching through holes so that the abrasive sheet may overlay the back up pad with matching hole patterns so that dust will travel through the abrasive sheet via a vacuum and into the holes in the back up pad and be collected by a dust collection receptacle. Such devices are inefficient at collecting dust as one skilled in the art would recognize that by placing a flat abrasive disc with through holes in it on a flat surface it is very difficult do direct vacuum to the through holes and efficiently apply the vacuum to the surface on which the abrasive disc overlays or is abrading. It is analogous to trying to suck air out of a bottle wherein no air is allowed to come into the bottle while attempting to suck air out of it. Herein lies the problem with the current technology of dust collection and abrasive tools. The present invention addresses this problem by providing an abrasive sheet material that has pathways in combination with through holes in an abrasive sheet so that the pathways are recessed below the abrasive surface and communicate with the through holes or apertures for the purpose of collecting dust. In this manner when the abrasive sheet material overlays a flat surface pathways exist in the abrasive sheet and the pathways become conduits that communicate with the dust collection holes in the abrasive sheet and in the tool to which it is attached. When a vacuum source is connected to the abrasive sheet the vacuum is directed into the pathways via through holes in the abrasive sheet and air is allowed to enter the pathways from the perimeter or outside the abrasive sheet thus air is swept across the work surface that is underneath the pathways bringing any dust that has accumulated in the pathway with it. The efficiency of dust collection is greatly increased as well as the cutting efficiency of the abrasive sheet since pathways also provide a plurality of cutting edges on the abrasive sheet material. By having dust collection pathways that are in direct contact with a work surface air is swept along the work surface by a vacuum applied to the pathway. In combination with air being swept across the work surface and air being taken in from outside the abrasive disc the ability to collect dust is greatly improved in comparison to the common abrasive disc having only through holes and no dust collection pathways.

SUMMARY OF THE INVENTION

It is an object of the present invention to increase the efficiency of dust collection while using abrasive sheet materials. The present invention increases the efficiency of dust collection by providing an abrasive sheet material that has dust collection pathways in combination with and in communication with dust collection apertures or through holes. The abrasive sheet comprises at least one pathway and at least one aperture wherein said at least one aperture communicates with the at least one pathway; wherein a vacuum is directed into the at least on pathway and at least one aperture The vacuum while in contact with the work surface beneath the pathways sweeps across the work surface by the movement of air though the pathways, dust with the air is moved from the work surface into at least one aperture wherein a vacuum is applied to the at least one aperture and to the pathways in communication with the at least one aperture.

More specifically the abrasive sheet comprises a first sheet and a plurality of second sheets positioned on the first sheet wherein gaps or spaces exist between the second sheets providing pathways between the second sheets. The abrasive sheet has a first major surface a second major surface and an abrasive first major surface wherein the pathways are recessed below the abrasive first major surface. At least one pathway extends from at least the first major surface or the bottom of a pathway to at least the second major surface. The pathways communicate with each other and with at least one aperture wherein the pathways and at least one aperture are used for directing vacuum to a work surface and for the collection of dust. And wherein the vacuum moves parallel with and in contact with the work surface by moving through the pathways between the work surface and the bottom surface of the pathway or the first major surface of the abrasive sheet. A more efficient means of collecting dust is achieved by using pathways in combination with dust collection apertures in an abrasive sheet material. One area where efficiency is greatly improved is by the sweeping movement of air along the work surface through the pathways as air travels through the pathways by means of a vacuum that is directed into the pathways via apertures in the abrasive sheet material. Dust with the air is then taken up into the apertures of the abrasive sheet material and removed by the dust collection apparatus to which the abrasive sheet material is attached. It is the objective of the present invention to provide an abrasive sheet material that has pathways and apertures that communicate with each other and with a work surface so that when a vacuum is directed into the pathways and apertures dust is removed from the work surface more effectively and efficiently by vacuum. It is also the objective of the present invention to provide an abrasive sheet that comprises a first sheet of material with a plurality of second sheets of material laminated to at least the first major surface of the first sheet and wherein the second sheets have open spaces or gaps between the second sheets and wherein the open spaces form pathways for the collection of dust. It is also the objective of the present invention to provide at least one aperture in the first sheet that communicates with at least one pathway wherein vacuum may be directed into the at least one aperture and into the pathways thereby forming a network of dust collection pathways in the abrasive sheet material for the purpose of collecting and removing dust from the work surface. It is also the objective of the present invention to provide a method of making an abrasive sheet material having pathways by kiss cutting second sheets from a sheet of material laminated to a releasable liner material wherein the second sheets are spaced apart from each other and delaminating the second sheets from the releasable liner material and relaminating the second sheets to a first sheet material that is not a releasable liner. It is also the objective to relaminate the second sheets to the first sheet with gaps or spaces that exist between the second sheets wherein the gaps form pathways between the second sheets for the purpose of creating a substrate suitable for coating with abrasive particles and forming an abrasive sheet material having pathways. Apertures may be punched into the abrasive sheet material in a secondary operation or may be formed in the abrasive sheet prior to coating the substrate with abrasive particles. It is also the object of the present invention to form an abrasive sheet material having pathways wherein the abrasive sheet material may not be a resilient abrasive sheet material. It is however within the scope of the present invention to use resilient materials or a combination of resilient materials and non resilient materials in making the abrasive sheet material of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment of the present invention

FIG. 2 is a side view of the embodiment of FIG. 1.

FIG. 3 is a top plan view of one embodiment of a disc formed from the abrasive sheet material of FIG. 1.

FIG. 4 is a top plan view of another embodiment of a disc formed from the abrasive sheet of FIG. 1.

FIG. 5 is top plan view of another embodiment of a disc formed from the abrasive sheet of FIG. 1.

FIG. 6 is a cross sectional view of FIG. 5

FIG. 7 is a top plan view of an alternate embodiment of the embodiment of FIG. 5.

FIG. 8 is a side view of the embodiment of FIG. 7

FIG. 9 is a top plan view of another embodiment of an abrasive disc of the present invention.

FIG. 10 is a top plan view of yet another embodiment of an abrasive disc of the present invention.

FIG. 11 is a top plan view of another embodiment of an abrasive disc of the present invention.

FIG. 12 is a top plan view of an alternate embodiment abrasive disc having concentric circular second sheets in segments.

FIG. 13 is a top plan view of an alternate embodiment of an abrasive disc having pathway segments that are concentric.

FIG. 14. Is a top plan view of an alternate embodiment of an abrasidve disc having pathways of a chain like configuration.

FIG. 15 is a top plan view of an alternate embodiment of the present invention showing a rectangular shaped abrasive sheet.

FIG. 16 is a top plan view of of an alternate embodiment of the present invention showing an abrasive disc having a hook and loop attachment system for attaching abrasive sheet to the disc.

FIG. 17 is a cross sectional view of the embodiment of FIG. 16.

FIG. 18 is a top planer view of the embodiment of FIG. 17.

FIG. 19 is a perspective view of another preferred embodiment of the present invention showing pathways opposite the abrasive side of the abrasive sheet.

FIG. 20 is a top plan view of an alternate embodiment of an abrasive disc of the present invention showing the back non abrasive side, the disc having concentric pathways in the abrasive surface, the pathways in communication with radial slots in the support sheet.

FIG. 21 is a cross sectional view of the embodiment of FIG. 20.

FIG. 22 is a top planar view of an a preferred embodiment of an abrasive disc having indented pathways.

FIG. 23 is a cross sectional view of the embodiment of FIG. 22.

FIG. 24 is a top planar view of an alternate embodiment of the embodiment of FIG. 22.

FIG. 25 is a side view of the embodiment of FIG. 24 showing a work surface.

FIG. 26 is a side view of an alternate embodiment of an abrasive disc having indented pathways opposite the abrasive surface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention is an abrasive sheet material 10 and a method of forming and making the abrasive sheet material.

The abrasive sheet material comprises a first sheet having a first major surface and a second major surface and second sheets having first major surfaces and second major surfaces wherein the second major surfaces of the second sheets are affixed to the first major surface of the first sheet and spaces exist between the second sheets wherein said spaces form pathways that interweave between the second sheets wherein the pathways communicate with each other and form a network of pathways and, at least one aperture extends from at least the first major surface of the first sheet to the second major surface of the first sheet and communicates with at least one of the pathways. Abrasive particles are coated onto at least the first major surface of the second sheets forming an abrasive first major surface.

During sanding operations wherein the abrasive sheet material is connected to a suction device that provides vacuum to the apertures and pathways of the abrasive sheet material air is sucked into the pathways from outside the abrasive sheet material. The vacuum or suctioned air is channeled through the pathways and provides moving air that is in contact with and flows or sweeps across the work surface, providing a flowing or sweeping movement of air that is in contact with the work surface while the air flows across and parallel to the work surface. The flowing or sweeping movement of air is caused by the vacuum or suction device. As the air flows across the work surface dust is collected and brought with the air through the pathways and into the apertures and is extracted into a dust collection receptacle.

Now in greater detail. FIGS. 1 and 2 depict an abrasive sheet material 10 comprising a first sheet of material 12 having a first major surface 14, and a second major surface 16 opposite the first major surface 14. A plurality of second sheets of material 18 are fixedly attached to the first major surfaces 14 of the first sheet 12 and spaced apart from each other forming gaps or pathways 30 between the second sheets 18. In the preferred embodiment the second sheets 18 are substantially smaller than the first sheet 12. First and second sheets together 12 and 18 respectively form a substrate 34 suitable for coating with abrasive particles. The second sheets 18 have a first major surface 22 and an opposite second major surface 24 and side surfaces 28. Abrasive particles are coated onto at least the first major surfaces 22 of the second sheets 18 or substrate 34 forming an abrasive first major surface 26 of the abrasive sheet material 10

The first sheet of material 12 may be considered equally as a support member, support layer, support sheet or reinforcing layer or the like and provides a backing or support for the second sheets 18. Although the first sheet may be considered a support layer or support sheet or reinforcing layer, for ease and clarity of description it shall be referred throughout this description as a first sheet.

The first sheet 12 is preferably made of a non resilient material such as paper. Other materials may be used for making the fist sheet material 12, such materials include but should not be limited to resilient materials, non resilient materials, cloth, fabric, foam, rubber, woven and non woven materials, mesh, mesh screen, screens, perforated sheet materials, plastic, resin, urethane foam, open and closed cell foam, cork, composite materials and loop or hook material of the hook and loop fastening system or a film. The second sheets may in an alternate embodiment be comprised of glue and not a sheet material wherein the glue has abrasive particles imbedded in the glue or wherein the glue attaches abrasive particles to the first sheet 12 so that pathways exist between the glue portions and wherein the glue portions are abrasive portions. The second sheets of material 18 may be comprised of any of the materials of the first sheet 12 as described above. The first and second sheets of material 12 and 18 respectively are preferably substantially flat and generally parallel to each other. The first sheet of material 12 preferably has a thickness in a range of about 0.002″ to about 0.005″. The first sheet is preferably rectangular and may be a continuous sheet or roll of sheet material. The second sheets 18 are generally smaller than the first sheet 12 and may be any conceivable shape including but not limited to round, square, rectangular, pentagonal, hexagonal, octagonal, triangular, circular, oval, oblong, half circle, waved, curved, diamond, disc shaped having a hole in the center or a circumferential ring or rings, or concentric circles. The second sheets of material 18 may be planar or non planar and not parallel to the first major surface 14. For example the second sheets may have a flat second major surface and a first major surface that is dome shaped, pyramidal, pointed, curved or any shape other than flat thereby forming an abrasive surface that is non planar. In the Preferred embodiment of the present invention the first sheet of material is substantially rectangular and generally flat or planar and the second sheets of material are substantially circular in shape and generally flat and planar. The second sheets of material 18 may be arranged in any pattern on the first sheet of material. Such patterns may include but should not be limited to concentric circles, gridded patterns, rows, off set rows, diamond shaped, circular, irregular, linear patterns, circular patterns. A combination of different shaped second sheets 18 may be arranged on a common first sheet 12 in a pattern that has either a functional or aesthetic purpose. For example a second sheet may be in the shape of a disc having an outside diameter and an inside diameter, wherein a plurality of second sheets are positioned with the inside diameter and wherein the second sheets may be square or circular or any other of the shapes mentioned. In this manner the second sheets 18 may form repeated patterns on a first sheet material 12 so that abrasive sheet products may be cut or punched from the abrasive sheet material 10 wherein the abrasive sheet product has a the particular pattern that is repeated on the abrasive sheet 10. For example second sheets may be arranged in a pattern of concentric circles and that pattern repeated on the first sheet thereby making an abrasive sheet material 10 having repeated patterns of concentric circles. In this manner a disc having concentric circles may be cut from the abrasive sheet material as described above and used on tools such as orbital sanders. Second sheets may for example be foam and the first sheet paper, or first sheet foam and second sheets paper. Alternately the first sheet may be a mesh screen and the second sheets made of paper or foam. Second sheet may also be attached to both the first major surface of the first sheet and the second major surface 16 of the first sheet and wherein abrasive particles are coated onto at least the first major surfaces 22 of second sheets wherein second sheets 18 are affixed to both the first and second major surfaces 14 and 16 respectively of the first sheet 12.

The second major surfaces 24 of the second sheets 18 are fixedly attached by adhesive to the first major surface 14 of the first sheet 12. It should be noted that the second sheets may be fixedly attached by flame laminating. The second sheets 18 are affixed to and positioned on the first major surface 14 of the first sheet 12 and spaced apart from each other forming gaps or pathways 30 between the second sheets 18. The pathways 30 serve as channels or form conduits when pressed against a work surface wherein the work surface acts as a wall of the conduit. The pathways or conduits direct or channel a suction force wherein the suction force moves air parallel to and in contact with the work surface while abrading the work surface. A plurality of vacuum holes or apertures 38 in the abrasive sheet material 10 extend from at least the first major surface 14 of the first sheet 12 to at least the second major surface 16 of the first sheet 12 wherein the apertures 38 communicate with the pathways 30 when a suction force is directed into the apertures so that the suction is dispersed throughout the network of pathways 30 thereby suctioning the dust away from the work surface while sanding. Apertures 38 and 44 may be considered pathway apertures. It should be noted that apertures and vacuum holes may be used interchangeably in the description of the present invention each of which equally describes a port for vacuum. In alternate embodiments as will be shown, apertures 42 may be configured and arranged wherin the apertures extend from the abrasive first major surface 26 to the second major surface 16 of the abrasive sheet material 10 wherein the apertures 42 may be considered substrate apertures. Apertures are preferably round but could be any shape including but not limited to round, oval, square, slots, curved, semi round or any suitable shape. The pathways 30 have sidewalls 32 that are in common with the side surfaces of the second sheets 18 and a bottom surface 36 that is in common with the first major surface 14 of the first sheet 12. The pathways 30 form a network that interweaves throughout and between the second sheets 18 and may have an arrangement and shape that is decided by the arrangement and shape of the second sheets and the second sheet side surfaces 28. For example the pathways may have a grid pattern that is generally rectangular wherein the second sheets are rectangular. The sidewalls of the pathways 32 may be substantially at a right angle to the first major surface 14 of the first sheet 12. The sidewalls may alternately be curved wherein the second major surface 24 of the second sheets 18 are dome shaped. The pathways 30 are recessed below the abrasive first major surface 26 of abrasive sheet material 10. In alternate embodiments wherein the second sheets 18 are not coated with abrasive particles the pathways are recessed below at least the first major surface 22 of the second sheets 18. It should be noted that only one second sheet may alternately be affixed to the first sheet 12 wherein the only one second sheet has openings that form pathways when the second sheet is affixed the first sheet 12. For example FIG. 13 has openings that are curved slots 88 wherein the curved slots may be considered pathways, wherein the pathway or curved slot communicates with apertures but not with other pathways. Referring now back to the pathways of the preferred embodiment of the present invention, the pathways 30 have a depth that is defined by the distance between the abrasive first major surface 26 and the first major surface 14. The width of the pathways is defined by the distances between the sidewalls 32 of the second sheets 18. The width of the pathways may be variable depending on the shape of the second sheets. One skilled in the art would recognize the need to keep the width of the pathways as small as possible while maintaining efficiency of directing suction through the pathways. It is desired that the largest amount of abrasive surface is maintained while in the abrasive sheet material 10 without sacrificing the effectiveness of the pathways to distribute suction to the work surface. For example, wherein the second sheets are square, the pathways may have a width in a range from about 1 mm to about 10 mm, more preferably from about 2 mm to about 5 mm. Wherein the pathways are circular the pathways will have a variable width, it is preferable in such instance that the narrowest distance between the second sheets 18 is in a range from about 1 mm to about 10 mm and more preferably from about 2 mm to about 5 mm. The cross sectional shape of the pathway may be v shaped, U shaped, square, rectangular or convex or concave or any shape formed by the sidewalls 32 of the second sheets 18 and the first major surface 14 of the first sheet 12.

An attachment means such as one part of a two part hook and loop attachment mechanism may be attached to the second major surface 16 of the first sheet 12. Loop material 40 is preferably used. Adhesive may alternately be used as an attachment means and applied to the second major surface 16. A pressure sensitive adhesive is preferable.

The apertures of the present invention are preferably pathway apertures 38 and are positioned within the pathways 30 so that the pathway apertures 38 extend from at least the first major surface 14 of the first sheet 12 to at least the opposite second major surface 16 of the first sheet 12. The pathway apertures 38 have a depth defined by the thickness of the first major surface or the distance between the first major surface 14 and the second major surface 16. Wherein an attachment material or mechanism is attached to the second major surface 16 of the first sheet 12 the apertures may extend through the attachment material. In such a case the depth of the apertures 38 would include the thickness of the attachment material or mechanism.

Apertures may alternately be positioned strategically throughout the abrasive sheet material 10 in patterns that coincide with patterns on back up pads such as back up pads for orbital sanders or the like. Such aperture patterns may include for example common five hole and eight hole patterns on orbital sander back up pads. Such hole patterns may be repeated in the abrasive sheet material 10 so that individual discs may be cut from the abrasive sheet material 10 that can be attached to the orbital sanders. It should be noted that the abrasive sheet material 10 may not have apertures and that apertures may be cut or punched into the abrasive sheet material 10 in a secondary operation or at the same time as cutting an abrasive sheet product from the abrasive sheet material 10. Wherein apertures are in hole pattern such as five or eight hole patterns the apertures would preferably not be pathway apertures 38 rather they would be substrate apertures 42 that extend through the substrate 34 from the abrasive first major surface 26 to at least the second major surface 16 and wherein an attachment means is attached to the second major surface the substrate apertures 42 would also exend through the attachment means attached to the second major surface 16. It should be noted that only one substrate aperture 42 or only one pathway aperture 38 may alternately extend through the substrate or pathways. In such instances where only one pathway aperture is used a large area of pathway may be formed by that area being devoid of second sheets 18. For example a large area of the first major surface 14 would not have second sheets attached to it thereby a large aperture may be place in the pathway and not extend through the second sheet material and only extend through the first sheet. Alternately a pathway aperture 44 that is larger than a second sheet 18 may be formed by displacing a second sheet wherein the larger pathway aperture 44 takes the place of a second sheet or otherwise displaces it. It should be noted that the apertures shown in FIGS. 1 and 2 are shown as examples of the different types and sizes of apertures and the number, size, quantity and type of apertures shown should not be considered in any way limiting the scope of the invention or otherwise indicate a pattern of apertures and the apertures shown are only for clarity in describing such apertures. It should be noted that alternately no apertures may exist in the abrasive sheet material 10 and apertures may be cut or punched into the abrasive sheet material as a secondary operation in making the abrasive sheet material as described below.

Abrasive particles are coated on at least the first major surface 22 of the second sheets 18 forming an abrasive first major surface 26. Abrasive may also be coated on the pathway sidewalls 32 and the first major surface 14 or any combination of surfaces including the first major surface 14 second major surface 16 of the first sheet 12 and first major surface 22 of the second sheets 18 and sidewalls 32 of pathways 30 and the present invention should not be limited by excluding any combinations of sides with or without abrasive coating. It is also within the scope of the present invention to not have abrasive coated onto any of the surfaces rather any of the surfaces may have a means of attaching an abrasive sheet. For example the second sheet material 18 may be a hook material of the hook and loop attachment system wherein an abrasive sheet having loop backing could be attached to the hooks and wherein the abrasive sheet may have apertures or openings that allow air to pass through the abrasive sheet including sanding screen. It should also be noted that first or second sheet materials 14 and 18 respectively may be a lamination or composite of materials for example second sheet material 18 may be paper laminated to hook material, or paper having an adhesive or adhesive film attached to the first major surface 22 of the second sheet 18 wherein the adhesive serves to attach an abrasive sheet material.

As previously mentioned abrasive products may be cut from the abrasive sheet material 10 wherein the abrasive products are for example circular or disc shaped. Such abrasive products may be used with tools including power tools such as orbital sanders and the like. Such examples of abrasive discs are illustrated in FIGS. 3-14.

FIG. 3 illustrates one such abrasive disc 46 cut from the abrasive sheet material 10 wherein the abrasive disc has circular or disc shaped second sheets and wherein the apertures are substrate apertures 42 that extend from the abrasive first major surface 26 to at least the second major surface 16. The substrate apertures in the present example have a five hole pattern that coincides with a common five hole pattern of back up pads on orbital sanders. Any hole pattern may be used other than a five hole pattern as dictated by the hole pattern of the tool to which the abrasive disc is to be attached. The holes in the back up pads of such tools are used for collecting dust, while using the tool to sand a surface. Vacuum is directed into the holes which in turn direct vacuum into the apertures 42 in the abrasive disc 46. The vacuum source may be an external vacuum source or an internal vacuum source provided by the tool. The pathways 30 of the abrasive disc extend to the edge or perimeter of the abrasive disc in multiple areas thereby allowing air to be sucked into the pathways from outside the abrasive disc when the disc is against a work surface and sanding.

The abrasive disc 46 may be cut from the abrasive sheet material 10 wherein no apertures are in the abrasive sheet material 10 and wherein apertures are cut into the abrasive disc in the same operation as cutting the abrasive disc from the abrasive sheet 10. Die cutting is the preferred method of cutting the disc as well as the apertures.

FIG. 4 illustrates another embodiment of an abrasive disc 48 the same as the disc described In FIG. 3 with the exception that the second sheets are square second sheets 50 and not circular and pathways 20 are in a grid formation.

FIGS. 5 and 6 show a top planer view and a cross sectional view of an abrasive disc 52 similar to the abrasive disc described in FIG. 4 with the exception that the apertures are pathway apertures 38 and not substrate apertures 42. Pathway apertures 38 are located within the pathways 20 and extend from the first major surface 14 to the second major surface 16 and wherein an attachment means is attached to the second major surface 16 the apertures 38 would extend through the attachment means. Loop 40 of the hook and loop attachment system is attached to the second major surface 16. It should be noted that in all embodiments of abrasive discs wherein the abrasive disc is to be attached to a back up pad it is preferable that loop material is attached to the second major surface 16 providing a means for releasably attaching the abrasive discs to a tool such as an orbital sander. It should also be noted that alternate means of attaching abrasive discs to tools are available and the present invention should not be limited to only those attachment systems mentioned here. For example abrasive discs may be attached by screw or clamping mechanisms used on palm sanders.

FIGS. 7 and 8 illustrate an alternate embodiment of a circular abrasive disc 56 similar to the one shown and described in FIGS. 5 and 6. In FIGS. 7 and 8 a second sheet is a circumferential circle or ring 54 that is located peripherally on the disc and provides a boarder. Square second sheets 50 are located within the ring 54. Pathways 58 do not extend to the outer edge of the disc 56, the pathways 58 are confined within the ring. The pathways within the ring comprise an enclosed chamber 62 when the disc is applied to a flat work surface. The enclosed chamber allows a negative pressure to accumulate wherein no pathways allow outside air to enter the chamber and by nature of an imperfect seal when the abrasive disc contacts a work surface 60 air is allowed to seep into the chamber between the work surface and the abrasive disc. The movement of air between the abrasive disc and the work surface is directed toward the pathway apertures and provides more efficiency in collecting dust, as dust is swept into the chamber and into the cust collection apertures before dust can migrate from the confines of the chamber. Alternately a limited number of pathways may be allowed to exit the chamber wherein the pathways intersect with the ring 54 and extend to the outer edge of the disc. One skilled in the art would recognize that the number of pathways allowed to exit the ring and still maintain a negative pressure within the chamber would depend on the amount of vacuum and size of the pathways, thus the amount of pathways exiting the ring should not exceed the point wherein no negative pressure is allowed to accumulate in the chamber. It is preferable the in a 5″ or 6″ disc that no more than 4 pathways are allowed to exit the chamber and still provide a negative pressure within the chamber. Such pathways are shown in phantom by numerals 64.

FIGS. 9-14 illustrate circular sheet abrasives that may be cut from the abrasive sheet material 10 wherein each figure shows different shaped second sheets 18 that are arranged in different patterns. FIG. 9 shows second sheets in a waved shape 66 that are positioned in rows. Pathway apertures are located in the pathways or between rows. FIG. 10 shows more than one second sheet 68 that is a concentric ring with circular pathways 70 between concentric rings. Pathway apertures 38 are positioned in the pathways. Pathway apertures may be any shape as previously described for example numeral 73 indicates an alternate slotted pathway aperture that is curved or of a semi circular ring shape. The slotted aperture 73 may be a concentric slotted aperture. It should be noted that the first sheet material 12 allows concentric circular rings to be held in position and supported via a common first sheet 12 thereby making it possible to position concentric rings on a back up pad without individually placing such rings on the back up pad one at a time. The pathway apertures 38 or 73 provide vacuum to the entire area or pathway between the concentric rings.

FIG. 11 shows hexagon shaped second sheets 72 with pathway apertures 38 that are in a pattern that coincide with the pathways between the hexagonal second sheets 72 so that the pathway apertures are positioned within the hexagonal pathways 76. Apertures may not be in a pattern that coincides with the hexagonal pathways and may be in any pattern such as random or in rows wherein the apertures would appear in the pathways at random. For example the apertures may be cut into the first sheet before second sheets are attached to the fist sheet. In such case the second sheets will cover some of the apertures and some of the apertures will fall in the pathways. Some apertures may only partially be covered for example numeral 78 shows a pathway aperture partially covered by a hexagonal second sheet.

FIG. 12 shows second sheets wherein segments of second sheets 80 together form a concentric circumferential ring that surrounds a single circular second sheet 84.The pathways 82 partition the second sheet segments 80. All pathways communicate with at least one substrate aperture 42. The substrate apertures 42 have a hole pattern that coincides with the hole pattern of a back up pad of a sander such as an orbital sander.

FIG. 13 shows an abrasive disc having a single second sheet 86 that has curved or semi circular slots 88 that are concentrically positioned and wherein the slots 88 extend through the second sheet but not the first sheet 12. The slots 88 form curved or semi circular pathways 90 that do not communicate with each other and each pathway 90 has pathway apertures 38 that extend through the first sheet 12 and into the pathway thereby providing vacuum to the pathway.

FIG. 14 shows a circular abrasive disc having a configuration of chain like second sheets 92 wherein the second sheets are in strips or rows having rectangular segments that are connected to each other to form a chain like structure. Pathway apertures 38 are located in the pathways 94 that separate the chain like second sheets. FIG. 15 shows a rectangular abrasive sheet product cut from the abrasive sheet material 10 having circular shaped second sheets 18. As previously described abrasive sheet products may be made by cutting or punching them from the abrasive sheet material 10 in a variety of shapes and sizes. For example FIG. 4-14 show only circular shaped abrasive products and FIG. 15 shows a rectangular abrasive product. It would be obvious to one skilled in the art that the shapes and sizes of abrasive sheet products that may be formed and cut from the abrasive sheet material 10 as well as the particular shape and sizes of second sheets of an abrasive sheet product is unlimited and the present invention only shows some preferred shapes and sizes. The present invention should not be limited in scope by variables such as shapes and sizes of second sheets, or pathways or abrasive products cut from the abrasive sheet material, or the size and shape and number of apertures or of the shape and size of the abrasive sheet material 10. Any combination of variables mentioned above and variables not mentioned but obvious to one skilled in the should be included within the scope of the present invention. The abrasive sheet material 10 is preferably in a continuous roll form but may also be in sheets that are not in rolled form.

FIGS. 16, and 17 illustrate a top planar view and a cross sectional view of a disc 96 having second sheets that are a hook material. FIG. 18 is a top planar view showing an abrasive sheet having apertures wherein the abrasive sheet is attached to and overlays the second sheets of hook material 19. In the present embodiment the second sheets are square second sheets 19 that are a hook material of the hook and loop fastening system. Abrasive sheet 21 having a loop material backing may attach to the hook material and overlay the pathways 30. The abrasive sheet 21 is shown in the cross sectional view FIG. 17 as attached to and overlaying the disc and pathways however for simplicity it is excluded from the top planar view of FIG. 16 so that the second sheets 19 and pathways 30 are easily recognized. The abrasive sheet 19 has through holes 23 for the purpose of collecting dust. When the abrasive sheet is positioned on the disc and overlays the pathways 30, some of the through holes 23 will overlay pathways 30 thereby suction that is directed into the pathways will access the through holes 23 as they overlay the pathways. Dust will travel through the through holes 23 into the pathways 30 and into the substrate apertures 42 and into the vacuum source receptacle. The abrasive sheet need not have through holes that are positioned to align with any particular pathway pattern. The abrasive sheet 21 may be configured with through holes in any pattern and positioned over disc 96 so that at least some of the through holes 23 will lie in part or in whole over at least some of the pathways 30 without deliberate positioning of through holes over pathways. For example the abrasive disc 21 may be placed in random positions on the disc without considering alignment of the holes relative the pathways and some through holes 23 will still at least partially overlay at least some pathways 30.

FIG. 19 is a perspective view of an alternate embodiment of the present invention with a partial cut away showing an abrasive sheet material 98 having an abrasive coating 102 on the second major surface 16 opposite the pathways 30 located on the first major surface 14 of the first sheet 12. The second sheets 18 are not coated with abrasive and have a ventilative attachment member 40 affixed thereto wherein the ventelative attachment member overlays the second sheets 18 and pathways 30. A preferable ventelative attachment member is loop material 40 of the hook and loop fastening system. Vacuum holes 100 in the loop material allow vacuum to access the pathways when the abrasive sheet is attached to a tool that has a vacuum source for dust collection and wherein at least one vacuum hole in the loop material communicates with at least one vacuum hole in the tool to which it is attached. Loop material 40 may alternately be affixed to the first major surface 22 of each of the individual second sheets 18 as shown by numeral 107 and not overlay the pathways 30. The pathways 30 are on the opposite side of the abrasive surface 102 and distribute vacuum to all apertures in the abrasive sheet. Apertures as described in previous embodiments may be pathway apertures 38 or substrate apertures 42. The apertures extend through the first sheet of material 12. A plurality of apertures may be positioned throughout the abrasive sheet material and at least one aperture 100 in the loop material 40 aligns with at least one vacuum hole in the tool to which the abrasive sheet is attached. In this manner vacuum is distributed to all the pathways thereby distributing vacuum to all apertures in the abrasive sheet. For example the abrasive sheet may be in the form of a disc wherein the disc is attached to a back up pad of an orbital sander and the back up pad has hooks of the hook and loop attachment system. At least one vacuum hole 100 may align with at least one vacuum hole in the back up pad of the orbital sander. It should be noted that the abrasive sheet 98 may have any attachment means fixed to the backing of the abrasive sheet and not only loop material for example adhesive may alternately be used as an attachment means. It would be preferable to have a vacuum hole pattern in the loop material 40 that corresponds to the hole pattern in the back up pad of the orbital sander, for example a five or 8 hole pattern is common in back up pads of orbital sanders. The holes in the loop material may extend through the second sheets and through the first sheet of material 12 and through the abrasive surface 102. In this manner the holes in the abrasive sheet may easily be aligned with the holes in the back up pad of the orbital sander. When the abrasive sheet is attached to the back up pad and in contact with a work surface all holes in the abrasive sheet would be substantially closed off by the work surface thereby vacuum would be distributed throughout the pathways 30 accessing all the apertures in the abrasive sheet and not only the vacuum holes that are aligned with the holes in the back up pad. Intake air would be provided through the side vents 104 of the abrasive sheet and also between the abrasive surface and the work surface. The side vents 104 are peripherally located on the abrasive sheet where the pathways 30 exit the sidewalls 106 of the abrasive sheet. Air is sucked into the pathways from outside the abrasive sheet, through side vents 104 and into the network of pathways 30. In this manner vacuum may be distributed to apertures positioned throughout the abrasive sheet via vacuum pathways located on the abrasive sheet opposite the abrasive surface.

An abrasive sheet may be made in this manner wherein side vents do not exist and a network of pathways form an enclosed chamber as described previously in FIGS. 7 and 8. For example an abrasive disc may have pathways opposite the abrasive surface wherein the pathways do not exit the sidewalls of the abrasive disc and form an enclosed network of pathways. It may be preferable that a limited number of pathways may exit the sidewalls thereby providing a vent in the sidewalls for intake air. The number of pathways allowed to exit the sidewalls would be determined by the amount of vacuum, the size of the vents and the area of the vacuum chamber as shown in FIGS. 7 and 8. It is preferable that the number of vents is such that a negative pressure is obtained in the vacuum chamber thereby a greater vacuum is distributed to the apertures in the abrasive sheet thus improving the efficiency of dust collection. In an alternate

FIG. 20 is a top planar view of an abrasive disc 108 having a support sheet 110 that is circular. The circular support sheet 110 supports concentric second sheets 112, 114, and 116 affixed to the circular support sheet 110 and shown in hidden lines. The concentric second sheets have abrasive material coated onto the surface opposite the side affixed to the support sheet 110 providing an abrasive major surface 128 on the second sheets. A cross sectional view of the abrasive disc 108 is shown in FIG. 21. The support sheet 110 has longitudinal slots 118 that extend through the thickness of the support sheet and are arranged in a radial pattern. The concentric second sheets 112, 114, 116 are sized and arranged so that when the second sheets are affixed to the support sheet 110, a plurality of concentric gaps or vacuum pathways 120 exists between the concentric second sheets. The concentric pathways 120 intersect and are in flow communication with the radial slots 118 in the support sheet 110. A fastener may be applied to the back of the abrasive disc for attaching the disc to a back up pad. Fasteners that may be used include hook and loop material of the hook and loop fastening system or adhesive, or any known fastener that serves to attach abrasive sheet to a back up pad. Loop material of the hook and loop fastening system is preferably used.

The outermost concentric second sheet 112 may be segmented into sections wherein each section is separated by a gap 122 and wherein the gap is a pathway that serves as an air intake port so that air may be sucked into the pathways 120 from the periphery of the abrasive sheet. Apertures 124 may be positioned on the support sheet and coincide with and occupy at least part of the space that forms the slots 118. The slots and apertures at least partially share a common space so that at least one slot communicates with at least one aperture. The apertures 124 extend through the thickness of at least the support sheet 110. from

For economy and simplicity in making the abrasive disc it is preferable that the apertures 124 are formed after the concentric second sheets are affixed to the support sheet and coated with abrasive particles. loop material 126 of hook and loop attachment system may be applied to the backing of the abrasive disc 108. If apertures are formed after support sheets 110 and second sheets 112,114, and 116 and loop material are laminated together, the apertures would extend through the thickness of the disc 108, extending through the loop material 126, support sheet 110 and second sheets 112, 114, and 116 and through the abrasive major surface.

Apertures may be formed by a punching or die cutting process. Additional curved slots 130 may be formed in the support sheet wherein the curved slots are segments of a circular slot having a diameter that allows the curved slots to communicate with vacuum holes in a back up pad irrespective of the alignment of the apertures 124 with the back up pad vacuum holes. For example if the abrasive disc 108 is attached to the back up pad of an orbital sander without considering alignment of apertures 124 with the holes in the back up pad, the curved slots 136 would have an increased chance of overlaying the holes in the back up pad.

FIGS. 22 and 23 show a top planar view and a cross sectional view of an alternate embodiment of an abrasive disc 132 comprising a substrate 134 having indented or embossed vacuum pathways 136 that are indented and recessed below the abrasive surface. In this embodiment the substrate is a non resilient material preferably paper. The abrasive disc 132 having embossed pathways is similar to the above described abrasive discs with the exception that the pathways are not formed by laminating second sheets to a first sheet rather the present embodiment comprises only one sheet that is a substrate for attaching abrasive particles thereby making an abrasive sheet or disc. The abrasive disc 132 has vacuum pathways 136 in a grid formation creating raised square surfaces that are coated with abrasive 140. Pathway apertures 138 are located in the pathways 136.

FIGS. 24 and 25 show a top planar view and a cross sectional view of a disc having indented vacuum pathways that do not exit the side of the abrasive disc as shown and described in FIGS. 7 and 8 above. FIG. 25 shows a cross sectional view of the abrasive disc in contact with a work surface 114

FIG. 26 shows a cross sectional view of an alternate embodiment of an abrasive disc 140 similar to the abrasive disc shown and described in FIGS. 22 and 23 with the exception that the abrasive surface is on the opposite side of the substrate that the pathways are indented or embossed into. The abrasive disc may be configured and arranged with pathways in any of the configurations previously described with the exception that they are indented or embossed into a substrate rather than formed by a kiss cutting and lamination process involving more than one sheet of material laminated together. Although an abrasive disc is shown it should be noted that an abrasive sheet in any of the above mentioned forms may be made using the embossing or indenting process to provide pathways to the abrasive surface or to the backing of the abrasive material opposite the abrasive surface. Although embossing and indenting an abrasive surface is not unknown in the prior art it is the intention to provide a new use for embossed abrasive articles wherein the embossed or indented portion provides pathways used for the purpose of dust collection wherein the pathways may be embossed in the surface that is to be coated with abrasive or the abrasive surface is embossed or indented after coating with abrasive. It is also the intent to provide an embossed or indented surface to the backing of an abrasive article wherein the embossed or indented portion provides pathways opposite the abrasive surface for the purpose of dust collection.

A method of forming the abrasive sheet material 10 comprises: Providing an abrasive sheet material comprising a first sheet having a first major surface and a second major surface and second sheets having first major surfaces and second major surfaces wherein the second major surfaces of the second sheets are affixed to the first major surface of the first sheet and spaces exist between the second sheets wherein said spaces form pathways that interweave between the second sheets wherein the pathways communicate with each other and form a network of pathways. At least one aperture extends from at least the first major surface of the first sheet to the second major surface of the first sheet and communicates with at least one of the pathways. Abrasive particles are coated onto at least the first major surface of the second sheets forming an abrasive first major surface. When air moves through the pathways by a vacuum source said pathways channel air across and parallel to the work surface while the air is in contact with the work surface thereby providing a sweeping movement of air across the work surface carrying dust with the air for the purpose of vacuuming dust from the work surface.

General Method of Making

Abrasive sheet product is made by providing a first sheet of material having a plurality of second sheets of material laminated to the first sheet of material wherein the second sheets of material are individual second sheets that are spaced apart and adjacent to each other thereby forming pathways or channels between the second sheets wherein the pathways form conduits for the passage of air and debris when the abrasive sheet product is in contact with a work surface and a suction or blowing air is directed into the pathways via apertures in the first sheet of material. Positive or negative air pressure may be directed into the pathways via a vacuum or air blowing device such as a fan, a vacuum is preferable.

In greater detail a plurality of second sheets of material are first formed by a method commonly known and used in making for example adhesive backed labels such as those sold in office supply stores. One example is a method of making Color Coding Labels such as those sold by Avery Dennison Corporation, product number 05795 wherein small ¼″ disc shaped labels are formed through a process of kiss cutting.

A second sheet of material is adhesively laminated to a first sheet of material. The second sheet of material being label material and the first sheet a releasable material that is releasably attached to the second sheet of material. The labels are formed into the second sheet of material by cutting through the second sheet of paper or the label material and not through the first sheet or the releasable material. The process of cutting only the second sheet and not the first sheet of material is a process called kiss cutting wherein the cutting blades of the machine cut through the second sheet and only touch or kiss the first sheet without cutting through it. Labels are now formed into the second sheet material forming individual second sheets that are spaced apart from each other. The second sheet material that is waste and not to be used as labels is removed from or delaminated from the first sheet material thereby leaving only individual second sheets or labels releasably attached to the first sheet and are adjacent to each other and spaced apart from each other wherein the spaces form pathways or channels between the second sheets or labels and wherein the pathways interconnect with each other and form a network of interconnected pathways that are in flow communication with each other. The space comprising the pathways or channels was previously occupied by the now removed waste material of the second sheet.

The abrasive sheet material of the present invention is made using the kiss cutting process described above wherein a second sheet of material is laminated to a first sheet of material wherein the first and second sheets of material are suitable materials for making a substrate for the purpose of coating the substrate with abrasive particles thereby forming an abrasives sheet material.

It should be noted that the above description is for the purpose clarifying the kiss cutting process in making labels and demonstrating how kiss cutting a second sheet of material laminated to a first sheet of material may be used in making a substrate for coating with abrasive particles wherein the substrate has pathways that are recessed below an abrasive surface or surfaces. The pathways are for the purpose of dust collection as will be further described.

It is the object of the present invention to use the process of kiss cutting to form an abrasive sheet substrate having a first sheet and separated second sheets laminated to the first sheet and pathways formed between the separated second sheets. Although it is the intention to use the process of kiss cutting in making the abrasive sheet material of the present invention some modifications or additional processes may be used in addition to the above process in making the abrasive sheet material and such modifications or additional processes are described below. In all such modified versions of making the abrasive sheet the common process of kiss cutting the second sheets is used. For example in some processes the second sheets may be kiss cut and delaminated from a releasable first sheet material to a first sheet of material that is not releasable thereby making the second sheets permanently affixed to the first sheet of material. In other embodiments the second sheets of material may remain on the releasable material and become more permanently affixed to the first sheet of releasable material by a make coat of adhesive used in the abrasive coating processes. Or the adhesive that bonds the second sheet to the releasable first sheet may be a releasable bond for a short period of time and become more permanent over a longer period of time thereby making the bond between the first sheet of material and the second sheets a permanent bond over time.

In the preferred method of making the abrasive sheet material a second sheet of material is laminated to a first sheet of material. A plurality of second sheets are formed from the second sheet material by kiss cutting the second sheet. The waste material of the second sheet is removed leaving a plurality of the desired second sheets releasably attached to the first sheet with pathways formed between the plurality of second sheets. The second sheets are then delaminated from the releasable sheet material and relaminated to a first sheet of material that is not releasable. It is also the object of the present invention to delaminate the second sheets of material after being kiss cut and relaminate the second sheets to a first sheet that is not releasable wherein the second sheets are in substantially the same pattern and arrangement as they were after being kiss cut and before delamination. In this manner any arrangement or pattern or formation of second sheets may be delaminated from one sheet and relaminated to a different sheet of material while maintainting substantially the same pattern and arrangement from one sheet to another sheet. It is the objective to keep the integrity of the positioning of second sheets in tact during the delamination and relamination process, it should be noted that a certain degree of misalignment or difference in positioning of second sheets when relaminated would not generally effect the performance of the abrasive sheet wherein the pathways provide a means of channeling vacuum to a work surface.

The delamination of the second sheets from the releasable liner and relamination to a first sheet that is not releasable material may be done by known machinery used in the paper converting industry and generally refered to as applicators. Such known applicators includes those made by Label-aire company Located in Fullerton, Calif. Preferable applicator machines that may be used for the delamination and relamination of second sheets are Label-Aire Model numbers 3115 wipe on, model 3135 wipe on, model 3114 Tamp Blow, model 3111 Air-Blow, 3125 wipe on, and 3155 wipe on. The wipe on applicators are more preferable. Although the company mentioned above and the applicator model numbers are preferable, the present invention and process of delaminating and relaminating sheets of material should not be limited to only these models, rather should include any known machinery used for delaminating a sheet of material from one sheet and relaminating the sheet of material to another sheet.

Machinery used for kiss cutting may be purchased from Manufacturers supply company in Cincinatti Ohio and includes such kiss cutting systems as the Guidolin Davide Systems model numbers GD151 Kisscut, GD301 Kisscut, GD401 Kisscut, GD654 Kisscut, Guillotine GDX1 and Rotary Die Kisscut. Rotary Die kiss cut is preferable for kiss cutting the second sheets of the present invention. The present invention may be made in two separate processes, the first process involves laminating the second sheets to a liner and kiss cutting the second sheets with a kisscutter machine then removing the waste material and winding the second sheets while on the liner into a roll. The second step involves putting the roll on an applicator machine described above and delaminating and relaminating the second sheets onto a first sheet of material for making a substrate with pathways as described. It should be noted that machinery as described above may be configured and arranged in a manner that combines the steps mentioned above into one step wherein a lamination of second sheets on a liner may be kiss cut then fed into an applicator wherein the second sheets are delaminated from the liner and relaminated to a first sheet wherein all steps are a continuous operation.

It is the intent of the present invention to use such machinery and processes as described above to efficiently and effectively make a laminated substrate having pathways used for dust collection and coating the substrate with abrasive particles to form an abrasive sheet material that has dust collection pathways. Through the process of kiss cutting, delamination and relamination, pathways are formed into the laminated substrate for the purpose of coating the substrate with abrasive material making an abrasive sheet material having dust collection pathways. Holes may be formed into the abrasive sheet wherein the holes direct vacuum to the pathways.

The second sheets of material may be of different shapes so as to form any configuration of pathways or form any pattern. For example second sheets of material may have a combination of shapes wherein some are rectangular and some are round, or some are curved and some are linear, and these combinations of shapes may form a pattern wherein that pattern serves a function and wherein that pattern is repetitively place or duplicated on an abrasive sheet material. individual abrasive products having a particular pattern of second sheets or sheet may be cut from the abrasive sheet wherein the abrasive sheet has a particular pattern duplicated on the abrasive sheet. It should also be noted that the second sheets provide individual cutting edges that increase the cut rate of the abrasive product and the particular shape of the second sheets may be of a shape that provides greater cutting efficiency by having many cutting edges. For example the second sheets of material may be star shaped, or have a wave pattern. The second sheets of material may have any imaginable shape including but not limited to circular, square, rectangular, octagonal, hexagonal, irregular, diamond, triangular, oval waved, curved, spiral, linear, non linear or any combination of these shapes including star shapes or concentric circles or any of these shapes wherein they are positioned to be concentric to each other.

Other devices may be devised and used to delaminate the second sheets from liner material and relaminate them to a first sheet material. It is the object of the present invention to include within its scope any and all devices that may be utilized for kiss cutting the second sheets that are laminated to a releasable liner material and delaminateing the second sheets from the releasable liner material and relaminating the second sheets of material to a first sheet of material wherein pathways or gaps exist between the second sheets when relaminated onto the first sheet material and wherein the first sheet and second sheets together form a substrate suitable for coating with abrasive particles thereby forming an abrasive sheet material and wherein the pathways of the abrasive sheet material may be used for directing vacuum to a work surface during sanding operations. Furthermore it is necessary that the first sheet of material is suitable as a substrate for an abrasive sheet.

The first sheet of material may serve as a backing layer or a support member or a first substrate or a connecting support member to which the second sheets are fixedly attached and that in the process of delaminating the second sheets from the releasable liner material and relaminating the second sheets to the first sheet material the integrity or positioning of the second sheets is maintained in substantially the same position they were in when kiss cut on the releasable liner material. The method of making the abrasive sheet described above provides unlimited possibilities of different configurations and arrangements of pathways that interweave between raised abrasive surfaces on an abrasive sheet wherein the raised surfaces are surfaces of the second sheets of material. It should be noted that the raised surfaces or second sheets may also not be coated with abrasive particles and the raised surfaces or second sheets may serve to retain an abrasive sheet material wherein the abrasive sheet material overlays the pathways and wherein the abrasive sheet material may have apertures that communicate with the pathways for the purpose of collecting dust.

An alternate method of making an abrasive sheet material of the present invention is similar the method described above with the exception that the second sheets are not delaminated from the first sheet of liner material after being kiss cut, and the first sheet of liner material is such that the second sheets may be releasable from the first sheet of liner material for a period of time then not releasable after a longer period of time wherein the second sheets over time become permantently attached to first sheet of liner material. For example the first sheet of liner material may be a sheet of material suitable as a substrate for coating with abrasive particles. The second sheet of material would be adhesively attached to the first sheet of liner material with an adhesive that for a short period of time allows the second sheet material to be releasable from the first sheet, herein after referred to as the releasable period. In this manner the second sheets may be kisscut and the waste material removed via a releasable attachment during the releasable period. After the waste material is removed a longer period of time passes and the second sheets become more permanently affixed to the first sheet of material. It is preferred that the second sheets become permanently attached to the first sheet of material before coating the substrate with abrasive particles. The second sheets however need not be permanently affixed to the first sheet and the adhesive bond may be made more secure during the abrasive coating process wherein a make coat of glue is coated onto the substrate covering the first major surface 22 of second sheets, the pathways 30, pathway sidewalls 32, and first major surface of first sheet 14 or pathway bottom 36. By coating all surfaces with glue, a secure bond holding the second sheets to the first sheet is achieved. The bond may be further strengthened by adding coats of glue during the abrasive coating process such as super make coats or any additional coat of glue otherwise used in the abrasive coating process.

It is well known that abrasive sheets are commonly releasably attached to back up pads by means of a pressure sensitive adhesive coating on the backing of the abrasive sheet. Although it is not the intent to make the second sheets releasably attached to the first sheet it should be included within the scope of the invention that a bond between the first sheet and the second sheets need not be permanent and that it may be of benefit to have the second sheets irremovably attached to the first sheet in certain instances.

Further modification of the invention herein disclosed will occur to those skilled in the respective arts and all such modifications are deemed to be within the scope of the invention 

1. An abrasive sheet material comprising: (a) A first sheet having a first major surface and a second major surface and second sheets having first major surfaces and second major surfaces wherein the second major surfaces of the second sheets are affixed to the first major surface of the first sheet and: (b) spaces exist between the second sheets wherein said spaces form pathways that interweave between the second sheets wherein the pathways communicate with each other and form a network of pathways and: (c) at least one aperture extends from at least the first major surface of the first sheet to at least the second major surface of the first sheet and communicates with at least one of the pathways. (d) Abrasive particles are coated onto at least the first major surface of the second sheets forming an abrasive first major surface; When the abrasive sheet is operatively connected to a suction device during sanding operations, air moves through the pathways, the air in contact with the work surface sweeps across the work surface carrying dust with the air and extracted from the work surface by the suction device.
 2. The abrasive sheet material of claim 1 wherein the abrasive sheet material is in the form of a disc.
 3. The abrasive sheet material of claim 1 wherein the second sheets are circular.
 4. The abrasive sheet material of claim 1 wherein the second sheets are square.
 5. The abrasive sheet material of claim 1 wherein the first sheet is made from a non resilient material.
 6. The abrasive sheet material of claim 1 wherein the second sheets are made from a non resilient material.
 7. The abrasive sheet material of claim 1 wherein the second sheets are adhesively affixed to the first sheet.
 8. A method of making an abrasive sheet material the method comprising: (a) providing a first sheet having a first major surface and a second major surface and second sheets having first major surfaces and second major surfaces, affixing the second major surfaces of the second sheets are to the first major surface of the first sheet and: (b) providing spaces between the second sheets wherein said spaces form pathways that interweave between the second sheets wherein the pathways communicate with each other and form a network of pathways and: (c) providing at least one aperture that extends from at least the first major surface of the first sheet to at least the second major surface of the first sheet and communicates with at least one of the pathways. (d) providing abrasive particles and coating the abrasive particles onto at least the first major surface of the second sheets, forming an abrasive first major surface; When the abrasive sheet is operatively connected to a suction device during sanding operations, air moves through the pathways, the air in contact with the work surface sweeps across the work surface carrying dust with the air and extracted from the work surface by the suction device.
 9. An abrasive sheet material comprising: (e) A first sheet having a first major surface and apposite second major surface and second sheets having first major surfaces and opposite second major surfaces wherein the second major surfaces of the second sheets are affixed to the first major surface of the first sheet and: (f) spaces exist between the second sheets wherein said spaces form pathways that interweave between the second sheets wherein the pathways communicate with each other and form a network of pathways and: (g) at least one aperture extends from at least the first major surface of the first sheet to at least the second major surface of the first sheet and communicates with at least one of the pathways. (h) Abrasive particles are coated onto at least the second major surface of the first sheet forming an abrasive major surface; When the abrasive sheet is attached to a back up pad of a tool and operatively connected to a suction device, air moves through the pathways, wherein the pathways are opposite the abrasive surface, the pathways form a conduit between the back up pad and the abrasive sheet and are in fluid communication with the at least one aperture thereby providing suction to the work surface via the at least one aperture.
 10. The abrasive sheet of claim 8 wherein the abrasive sheet material is in the form of a disc
 11. The abrasive sheet material of claim 8 wherein the first sheet is made from a non resilient material
 12. The abrasive sheet material of claim 8 wherein the second sheet is made from a non resilient material. 